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By A. Koizhanova

Kumistinskoye gold- and silver bearing ores (Republic of Kazakhstan) as well as standardized test solutions containing gold, silver, copper, zinc and iron were studied. The best results in silver and gold recovery from Kumistinskoye gold- and silver bearing ores were achieved through use of complex cyanide-thiosulfate solutions as compared to individual cyanide solutions and thiosulfate solutions. It was found that such complex solutions substantially step up leaching process herewith increasing precious metals recovery rates. Thermodynamics of studied chemical processes was calculated. Reaction order, kinetic constant and activation energy of gold leaching process through use of cyanide-thiosulfate solutions were identified. We managed to prove that the sorption rates and holding capacity in process of gold anions recovery with anionite AM-2B are comparable to sorption characteristics for cyanide solutions. Keywords: gold, silver, copper, zinc, iron, cyanide-thiosulfate solutions, anionite AM-2B

Sep 1, 2012

By A. Oberrauner

Electrostatic separation is a dry separation technique usable for many applications in the mining- and recycling industries. At the Chair of Mineral Processing intensified research has been done on this topic during the last years. One challenge was to measure the triboelectric charging of fine mineral particles in a triboelectric charging device consisting of an electrically insulated polyethylene rotor/stator assembly. These tests, performed on monomineralic samples, were accomplished in a climate chamber. It was shown that charging of minerals not only depends on rotor speed, feed rate and atmospheric circumstances but also on the properties of the applied electrostatic field. Tests on pure calcite in contact with the polyethylene rotor/stator system resulted in specific triboelectric charges up to +10 nC/g at low relative humidity. With more water present in the surrounding atmosphere, these charging values decreased significantly. However, at higher relative humidity, triboelectric charge values could be maintained after an electrostatic field of positive polarity was applied. Similarly, charging behavior was found with other hydrophilic minerals. The idea behind all these tests was to find the largest charging difference between minerals occurring together in a deposit and to be able to charge them oppositely, assuming that this means good sort ability in an electrostatic separator. The results gained from these investigations are shown. After having obtained many results on charging pure minerals, it became interesting to test the applicability of the charging tendencies on electrostatic separation of fines <100 µm. In order to do so, a separator for fine polymineralic powders was developed, constructed and combined with the triboelectric charging device, all being set up in a climate chamber. This new so-called coax-separator is presented along with first test-results.

Sep 1, 2012

By Sanjay Agarwal

Polymetallic sea nodule is a good source of manganese having 22.3% Mn, 5.4% Fe, 6.14% Si, 1.1% Cu, 1.15% Ni, 0.076% Co & others. These nodules are available in plenty on the sea beds, generated over thousands of years. Nodules mainly consist of manganese dioxide and iron oxide phases and other metals are entrapped in the complex cage of these Mn-Fe oxides phases.World-wide research is going on sea nodules as an alternative future source of many metals, which has led to intensified efforts to develop practical and economical processes for recovery of these metals. Very little attempt has been made world over on manganese extraction from sea nodules. We at CSIR-NML, India have developed a direct reduction smelting process of nodules to recover manganese as Fe-Si-Mn alloy. This alloy is extensively used in the steel industry as deoxidizer and as an alloying element to make different grades of steel. Lab scale experiments were conducted to study the manganese distribution between Fe-Si-Mn alloy and FeO-SiO2-MnO-CaO-Al2O3-MgO slag at different temperatures by varying the basicity of the slag. The direct reduction smelting of nodules is carried out on 1 kg scale in 50 kVA electric arc furnaces to have Cu, Ni and Co alloy and Mn rich slag. This manganese rich slag is further treated in 50 kVA arc furnace to produce Fe-Si-Mn alloy. The composition of Fe-Si-Mn alloy obtained is in the range of Mn: 60-65%, Si: 14-17%, C: 1- 2%, S: 0.03% and the balance iron which is acceptable grade for industrial use. The equilibrium amount of MnO in the final slag is controlled by the temperature of the final melt and the silica, lime, alumina content of the final slag. Increasing the basicity of the slag plays a major role in minimizing the loss of MnO to slag, increasing the amount of SiO2 of the slag, increases the manganese loss in the slag. Increasing the CaO/ Al2O3 ratio of the slag decreases the manganese loss in the slag. Increasing the MgO/CaO ratio of the slag increases the manganese loss in the slag. Thus by adjusting

Sep 1, 2012

By M. Saba

In cyanide leaching procedure, achieving an acceptable efficiency for silver and gold is very time-consuming, thus, enough studies have not been performed for optimization and modeling of this process. The kinetics of cyanide leaching includes two steps: first step comprises a sharp slope while the other has a slight increasing trend. In the present study, in order to reduce the time and cost, the cyanide leaching process of a sulfide silver/gold ore was optimized in the first period. The applied parameters and their ranges are: temperature 20-40 (°C); time 1-8 (hrs); cyanide concentration 1-2 (mole cyanide / mole Cu); the percentage of solid to liquid 1-2 (%) and pH 10-12. For design of experiments fractional factorial 2(5-1) was used. Also four center points were applied to increase the accuracy of the model. In addition, by analysis of variance (ANOVA) the most effective parameters were identified and the optimized condition was determined. A regression model was proposed to describe the effects of independent variables and their interacting role on silver recovery. Results showed that the model was linear for silver and nonlinear for gold. In the gold recovery process, the two important parameters are time and pH with the former being more effective. Due to the existence of cyanide ions in the medium, temperature and cyanide concentration have less influence in the gold recovery process. Solid to liquid ratio, in addition, comprises a slight negative impact on the procedure. This emphasizes the different kinetics of silver/ gold cyanide leaching. Finally, using the optimum condition the amount of silver and gold obtained were 61% and 67% in 8 hours, respectively. While in general conditions, the results were 37% and 54% in 24 hours, respectively. Keywords: cyanide leaching, refractory gold/silver ore, modeling, optimization

Sep 1, 2012

By V. A. Ivanova

Modification of hydrophobic part of carboxylic collector molecule is an upcoming trend for producing new reagents and changing its flotation properties such as activity, selectivity, sensitivity to hardness salts that inevitably present in the pulp liquid phase in the processing of ores containing calcium minerals. A wide range of apatite collectors ? monoalkyl ethers and monoalkylamides of dicarboxylic acids ? succinic, o-phthalic and maleinic acids have been synthesized by the addition of aliphatic alcohols and amines with various hydrocarbon radical value (from ?11 to ?16) to anhydride of the corresponding acid. Using computer modeling based on ChemBio 3D program of specialized complex Chem?ffice the calculation was carried out of charge distribution on atoms, energy parameters of molecules for investigated compounds. Calculated values of absolute hardness (?=6.75 ? 12.36) and absolute electronegativity (?= 5.67 ? 8.90) of the reagents showed that monoderivatives of dicarboxylic acids refer to the ?hard? type of bases. The degree of a charge transfer during calcium compounds formation of considered collecting agents (?N=0.009 ? 0.143) has been computed. Dissociations, micelle formation in solutions of these reagents and its hydrophobic and collecting properties were investigated in respect to apatite. Dependence of bulk, surface and collector properties on collector molecule architecture (double bond or benzene ring and non-ionogenic functional group in the structure of hydrocarbon radical) has been established. It is shown that experimentally determined dissociation constants (??a=5.16 ? 5.60 for succinic acid derivatives and ??a=3.32-3.78 for maleinic and o-phthalic acid derivatives) perfectly correspond to acidic properties predicted by computer calculations. Compounds of monoalkylderivative dicarboxilic acid have been determined optimum in composition and structure. The results of apatite flotation from apatite-nepheline ores of the Khibiny deposit (the Kola Peninsula) are presented here and show benefits of selected reagents. Keywords: monoalkylderivatives, dicarboxylic acids, reagents, microflotation

Sep 1, 2012

Results of the study of chloride ion concentration effect to osmium-187 sorption from wastewater of copper smelter with use of foreign anionites of different basicity and structure are presented in the work. It was found that the increase of chloride ion concentration in the wastewater helps to increase recovery of osmium using anionites regardless of their nature. The ways to intensify the process are proposed. The method for osmium elution from the anionites with potassium iodate solution was developed. It was shown that the method lets to recover up to 99% of osmium from the anionites. Recommendations for selection of eluents for better recovery of osmium from the anionites were elaborated. Keywords: wastewater, osmium, anionite, sorption, chloride ions, eluent, recovery

Sep 1, 2012

By S. K. Chaurasiya

o meet the ever increasing demand of iron oxide feed stock for rapidly growing domestic steel industries and to effectively manage the depleting reserve of high grade lumpy iron ore, Pelletization of iron ore fines/slimes are expected to play a dominant role in the near future. Use of pellets will also enable the blast furnace operator to achieve higher levels of productivity with lowering of operating cost. The effective utilization of Iron Ore Slimes is important not only from the point of view of optimum utilization of Iron values in the mined ore but also for preventing environmental pollution. A significant amount of slime is being accumulated at the tailing dam of one of the iron ore mines and with the present scale of operation the tailing dam will be filled in another 10 years. Hence to increase the life of tailing dam and for better utilization of the iron values a study has been carried out for the suitability of pellet manufacturing with slimes and fines at our laboratory. The pelletization studies are aimed for optimization of various parameters for production of Blast furnace/ DR grade pellets from beneficiated slimes and Fines. This paper attempts to describe the production of blast furnace grade pellets from beneficiated slime and fines and its characterizations.

Sep 1, 2012

By H. R. Manouchehri

Large variations in flotation characteristics of minerals have been observed in winter and summer in plant practices as a result of changes in pulp temperature. Variations in temperature may affect the quality for pulp and related process water through changes in dissociation of different chemical species within the pulp, as well as changing in gas and metal hydroxide solubility, reagent adsorption and its stability on mineral surfaces, water/pulp viscosity, etc. All of these affect the flotation characteristics of specific mineral to some degree or another. It has been observed in Cu-Pb-Zn and/or Pb-Zn sulfides flotation that sphalerite (ZnS) flotation is strongly affected by changes in pulp temperature. Plant practices have shown that at the both low, e.g., T <10-12°C, and high, e.g., T > 60°C, the recovery for copper activated sphalerite is dramatically dropped. Within this paper the effect of pulp temperature on flotation characteristics of sphalerite is brought into considerations and laboratory flotation tests were conducted in conjunction with surface and solution chemistry analysis to understand the effect of temperature on sphalerite recovery. The effect of temperature seems to be complex since the temperature affects both the physical (hydrodynamics) and chemical phenomena in the flotation cell. In fact all sub-processes in flotation, i.e., collision, attachment and detachment, are affected by changing in temperature. Experimental results indicating that at alkaline pH values, e.g., 8.5 to 10.5, the recovery for copper-activated sphalerite is dramatically reduced when temperature is below 10-12°C, which is in agreement with plant practice at Boliden?s Garpenberg plant in Sweden. However, results from other studies indicated that the zinc recovery is also considerably decreased at high pulp temperatures, i.e., 62°C and above.

Sep 1, 2012

By Tasuma Suzuki

Electrokinetic/permeable reactive barrier system is a promising in situ soil and ground water remediation technique to reduce toxic NO3- into less toxic NH4+. Using granular zero-valent iron (Fe0) as a reductant, the first objective of this study was to investigate the influence of the solid-liquid ratio and aqueouspHon NO3- reduction. The results obtained from a series of batch experiments showed that NO3- reduction was enhanced by either increasing solid-liquid ratio or decreasing aqueous pH. Based on insights obtained from batch experiments, the second objective of this study was set to design the remediation conditions of the electrokinetic/Fe0permeable reactive barrier system to maximize the NO3- reduction efficiency. Experimental results showed that the effectiveness of the system strongly depended on the Fe0 percentage in the reactive barrier, the pH in the anode reservoir, and the applied voltage, which were consistent with the results obtained from batch experiments. Under optimized treatment conditions, nearly 100 % NO3-was reduced into NH4+ in the permeable reactive barrier and collected in the cathode reservoir. Insights obtained from this study provided fundamental information on roles each of remediation design parameters plays, and will be useful to optimize the remediation conditions. Keywords: electrokinetic remediation, permeable reactive barrier, zero-valent iron, nitrate

Sep 1, 2012

By A. Kurkov

Flotation process is based on the formation of primary collector-based supramolecular associates at the mineral surface and within the pulp. Supra molecular chemistry allows studying within a common framework, all kinds of molecular associates, from dimers to large assemblies, resulting from spontaneous association of a large number of interacting components of the flotation system, where the collective action of non covalent bonds can have an important role. Self-organization of supra molecular assemblies in the flotation process can be controlled by modifying the chemical structure of the collector, the nature and arrangement of functional group in it, by introducing secondary agents (SA) into the process, to adjust the interaction between the collector and the surface and to control the hydrophobicity of the adsorption bed. This offers broad opportunities to build supramolecular assemblies to improve the efficiency of flotation. Besides, the more complex is the system, the weaker are the interactions, that determine its behavior. This powerful factor still is not employed deliberately to control the flotation process. Organophosphorus compounds (OPC) - dialkyl phosphoric acids whose radicals contain ethoxylated groups ? are considered as nanocompounds, that can be used in building supramolecular assemblies. The presence in an OPC molecule of functional groups (P=O, P (O) O-, P (O) OH), ethoxylated groups, and aromatic rings is the basis for the formation of stable supramolecular associates. Gross formula: C54H94KO16P. Molecular weight is 1069.39. Phosphoryl anion has a regular tetrahedral structure with the angle of 109.5°. Lengths of -P-O- bonds in a PN molecule are 1.7345Å; length of the hydrocarbonic radical C42-C72 = 33.942Å. In an alkaline environment, PN is in the form of the anion, in an acidic environment ? in the form of the polycation due to protonation of the oxygen in the EO group. Chem Office software suite was used to generate three-dimensional images of an OPC molecule in acidic and alkaline environments, to reveal the OPC geometry (bond lengths, valence angles, aliphatic radical length), to identify the collector&apos;s binding sites with the mineral surface, to find the most stable and energy-efficient molecular conformations of an OPC molecule and its complexes with minerals under various conditions. Mechanisms of interaction between OPCs and the mineral surfaces are different. In ores whose minerals are dominated by ionic bonds (fluorite), the interaction mainly involves the anionic form of the collector; in ores, whose minerals are dominated by covalent bonds - the oxygen of the phosphoryl group (donor-acceptor interaction) and the oxygen of the ethoxylated groups. This difference is responsible for the formation of spatial associates with different surface layer structures. Introduction of supramolecular chemistry concepts into the analysis of flotation phenomena and mechanisms can become an effective tool for better understanding the flotation process and offers new means of consistently improving its effectiveness.

Sep 1, 2012

By N. P. Haran

A detailed study was undertaken to beneficiate sub-grade iron ore sample from Kenojhar District, Orissa, India containing 57% Fe (T), 7.7% SiO2, 4.8% Al2O3, 4 % L.O.I. 0.4% TiO2,1.3 % Mn and traces of S(T) to make it suitable for the user industry. The mineralogical study indicated that it predominantly consists of haematite with subordinate amounts of goethite and clay. Quartz, Cryptomelane / Psilomelane, Pyrolusite, Gibbsite, Feldspar and Muscovite mica were present in very minor to trace amounts. The Denver grind ability tests indicated, that the sample could be categorized as ?medium soft to medium.? The Bond ball mill work index was determined to be 14.19 kwh per short ton. The beneficiation process involved classification followed by tabling of the classified sand, ground to minus 48 mesh size. The table slimes were subjected to Wet High Intensity Magnetic Separator (WHIMS). The developed process yielded a composite concentrate from tabling and WHIMS operations assaying 65% Fe(T), 2% SiO2, 1.8% Al2O3, 2% Mn and 0.9% LOI with a recovery of 60.1% Fe (T), amounting to 52.5 wt.% yield. To meet the size specifications for pellet making, it was further ground. Dewatering studies were also carried out on the ground combined concentrate and rejects. The thickener area of ground combined concentrate using 0.02 kg/t of Sufloc A 1115 flocculant was 0.02 m2/tonne of dry solids per 24 h. And for the combined rejects using 0.12 kg/t of flocculant, it was 0.035 m2/tonne of dry solids per 24 h. The moisture content, in the pressure filtration cake, in the ground combined concentrate product was 10.0%, and productivity was 506.7 kg/m2h. Thus, by thickening and filtration of process products, 90% of water used in the process could be recovered. The study highlights the development of a simple and cost effective flowsheet with almost complete water recovery for a subgrade iron ore sample. Keywords: tabling, WHIMS, thickener, filtration

Sep 1, 2012

By Dongyun Liang

Process mineralogy focuses on the chemical components and mineral composition of ore, dissemination size of valuable minerals, the occurrence of valuable and detrimental elements as well as the behavior of each mineral in the process. Through determining process mineralogy parameters and analyzing the characteristics of minerals, the results of process mineralogy study can provide mineralogy data for making a reasonable mineral processing technology program and optimizing the process. A detailed process mineralogy study is carried out for a complex rare metal ore in this paper and the results show that niobium mainly exists in the form of ferrocolumbite as well as nioboaeschynite and zirconium primarily occurs as zircon. The valuable minerals including Th-nioboaeschynite, ferrocolumbite, zircon, etc. have the characteristics of fine dissemination size, wide size range, complex chemical composition and variable physical properties, which mean it is a refractory ore. According to the results of mineral composition of ore, chemical composition of minerals, dissemination size of minerals, magnetism ranges of minerals and the distribution of niobium and zirconium, the process of ?desliming-Nb-Zr bulk flotation? is designed for this ore and the niobium-zirconium bulk rough concentrate with the grade of Nb2O5 9.43%, ZrO2 24.95%, Ta2O5 0.36% and the recovery of Nb2O5 77.66%, ZrO2 76.70%, Ta2O5 75.13% to crude ore can be obtained in the whole process closed-circuit test.

Sep 1, 2012

By Avishan Atrafi

Frothing behavior of surfactants originate from their preferential adsorption at the gas-solution interface. Different surfactants may demonstrate different adsorption behaviors depending on their molecular structure and surface activity. The quantity and rate of adsorption of surfactants at the gas- solution interface in flotation systems will certainly affect kinetics of reaction and fractionation of surfactant between bulk and foam phase and subsequently their frothing characteristics. In this paper, the frothing characteristics of sodium oleate which is the main constituent of fatty acids used in flotation systems is explained. The adsorption behavior of sodium oleate is then compared to a typical non-ionic frother (Methyl Isobutyl Carbinol, MIBC) in terms of different adsorption behavior at the gas-solution interface. Since long chain fatty acids are weak electrolytes, their behavior is a strong function of pH. Also semi soluble salts including apatite contain considerable amounts of ions like calcium in their lattice, so the effect of presence of ions on the frothing behavior of fatty acids requires an investigation. A mass balance on the surfactant transferred to the foam was solved to estimate the bubble surface area flux in foam, which explained how the adsorbed surfactant at gas-solution interface controls the bubble surface area flux at foam. Since sodium oleate adsorption at foam takes place gradually, frother concentration as a function of time was monitored by the total organic carbon measurement (TOC) to compare the surfactant uptake rate at different concentrations, pH and ionic strength. The surfactant concentration adsorbed within foam together with the value of adsorption density from the Gibbs adsorption, leads to the calculation of the surface area flux and prediction of average bubble size in the foam at a specific time frame. This value was compared at different concentrations of sodium oleate. Dynamic surface tension measurements were accompanied to explain the adsorption behavior, though finally equilibrium surface tension turns out to better explain the foamability characteristics. Keywords: flotation collectors, flotation froths, foams, fatty acids, adsorption behavior

Sep 1, 2012

By Q. Shi

An investigation into the hydrophobic aggregation of ultrafine smithsonite in surfactant solution has been undertaken through a combination of hydrophobic flocculation experiments, zeta potential measurements, surface tension measurements, and contact angle measurements. The experimental results have revealed that the behaviors of hydrophobic aggregation were closely correlated with the particle hydrophobicity, but they were not lowered byte change of the particle surface charges due to surfactants adsorption. On the other hand, the liquid (solution) surface tension (?LV) plays an important role in hydrophobic aggregation, and the hydrophobic aggregation could not occur below the critical liquid (solution) surface tension (?c). Meanwhile, this flocculation has been observed to require sufficient stirring strength and magnitudes of kinetic energy input to achieve the maximum aggregation degree. From the microflotation results, it has been found that the flotation kinetics response of smithsonite fines is markedly improved due to sufficient stirring strength, and the stirring strength influenced the floc flotation in a manner quite similar to their influence on the hydrophobic aggregation, suggesting that the formation of hydrophobic flocs is a promising means to recover smithsonite in the fine size range.

Sep 1, 2012

By D. Chen

The experiment adopted magnetic separation-priority flotation (first to float copper,then float lead) combined technology to deal with a complex Cu,Pb ,Zn multi-metals ore which has high sulphur content, difficult to separate Cu, Pb ,Zn minerals from sulphur and separate Cu from Pb. Floatable pyrrhotite was separated through magnetic separation which could eliminate the adverse effect on the flotation followed up. And then adopting the priority flotation process to recover the Cu, Pb ,Zn from the magnetic tailings. In priority, flotation Cu, BP(a kind of ethionine ester collector ) and ethyl xanthogenate were used as the collector, LD-1 and sodium sulphite were used as the depressant.The depressants combined with humic acid sodium and lime were used for chalcopyrite ? pyrite separation to further improve the copper concentrate grade. Considering the raw ore that contain 0.32% copper, 0.54% lead and 25.54% sulfur. The copper concentrate grade is 23.61%. The lead content of copper concentrate is only 0.85% . The recovery of copper is 75.03%,and the lead concentrate grade is 54.58%, the copper content of lead concentrate is only 0.81% and the recovery of lead concentrate is 62.24%. The mineral processing indexes were excellent, finally realizing the high effective separation of Cu, Pb , Zn and pyrite. This technique provides a new approach to highly utilize complex copper-lead-zinc ore.

Sep 1, 2012

The present study is devoted to improvement of the leaching efficiency during phosphorous removal from high phosphorous gravity-magnetic concentrate. Before leaching the concentrate has been subjected to roasting with the addition of either Ca(OH)2 or CaO. The oolitic iron ore is roasted at 900°C for one hour. This reflects in reaction between alkaline earth additive and quartz, aluminosilicates, phosphorus, and some other minor components of the gangue minerals. The application of leaching, physical separation, and wash out of salts has resulted in the decrease of phosphorus from 0.7 to 0.15 % and it is established that the major influencing factor is the concentration of acid and to a less extent duration of the leaching process. About two third of the phosphorus can be removed by roasting with 3 % CaO to hematite, coarse grinding to d50 0.3 mm, dry high intensity magnetic separation and leaching of the magnetic fraction with hydro-chloric or nitric acid.

Sep 1, 2012

By Y. J. Ferdosi

This paper presents the outcomes of the preliminary investigation focused on the potential usage of Electrochemical Impedance Spectroscopy (EIS) in minerals processing. Currently, Electrochemical Impedance Spectroscopy has been successfully employed in the characterization of multilayer structures formed as molecules adsorb on flat surfaces and is commonly used in bio-related research. Few studies have explored the application of EIS in minerals processing, particularly for mineral particles and flotation systems. In the first series of tests, the impedance response was investigated as a function of particle size, shape and hydrophobicity using model quartz particles. The particle size fractions and the shape were found to contribute to the impedance response. The more hydrophobic quartz particles resulted in a higher impedance values. Further tests involved pure sulfide minerals including chalcocite, bornite, chalcopyrite and pyrite. The AC impedance measurements were conducted as a function of collector (sodium ethyl xanthate) dosage. The AC Impedance data was modeled using the combination of reference circuits. It has been shown that adsorption of collector onto sulfide minerals surfaces results in a higher magnitude of impedance. Increasing the collector dosage resulted in an increase in AC impedance for chalcopyrite, while a decrease was observed for chalcocite. Significant variations in impedance were exhibited by bornite and pyrite with a gradual increase in collector dosage.

Sep 1, 2012

By M. M. Kulkarni1

Kaolin clay is used as a filler and pigment in various applications such as paper, paint, rubber, plastics, adhesives, ink and ceramics etc. Major mineral content in crude kaolin clay is kaolinite along with some accessory minerals as quartz, hematite, mica, feldspar, anatase, rutile, illemnite etc. The Fe and Ti bearing minerals play very important role in determining quality of the kaolin, as these minerals impart yellow, pink or darker color to the white kaolin. Conventional beneficiation methods used in kaolin processing are de-gritting, classification and sodium dithionite bleaching, which improves the optical properties of kaolin, wherein reduction of color imparting constituents such as Fe2O3 and TiO2 is marginal. In the present study, these coloring impurities are separated using selective adsorption of water-soluble polymers. Degritted kaolin samples after passing through 45 micron sieve is used in the study for selective flocculation by polyacrylamide based polymers. The effect of pH, zeta potential, and polymer dose on the reduction of impurities is studied. Analytical tools such as XRF, XRD, SEM, and TEM techniques are utilized and results are discussed in detail.

Sep 1, 2012

In looking to the future of mineral processing the focus is typically on improved processing units. Basically it is a search for an elusive wonder machine that could revolutionise the economy of mining: the sorter that strips 50% of the ore with only a few % loss of value; the comminution device that uses 5% of the energy while producing fully liberated particles; or the recovery device capable of producing a 99% recovery at 99% grade. These aspirations are propounded against a reality backdrop of sorters rusting in back yards, mill throughputs below design and varying by 30%, cyclones flaring and cut-sizes fluctuating, mediocre recoveries and soaring processing costs. This disconnect between aspiration and reality appears, to these authors at least, to be a mighty chasm. Moreover, it remains one over which we are expected to magically leap rather than methodically bridge. Indeed one may be forgiven for thinking that should such a wonder machine come along, taking advantage of it would be highly improbable. Questions would inevitably emerge on how to feed the correct material, how to cope with the wide variability of feeds, how to control such advanced equipment and how to handle the new product from such a machine. It is likely these questions might lie unanswered, or more regrettably, unasked. It is generally accepted that as an industry we are exceedingly unlikely to teleport from the current status quo to an entirely new reality in a single flash. It is our thesis that the probability of these magical machines materialising is remote, and even if they miraculously appeared, we simply wouldn?t know what to do with them. Rather, it is our contention, that a step change will only arise through a staircase rather than from a single giant leap. We should focus on building those steps and linking them together into a firm structure ? a workable mineral processing circuit. This paper addresses the alternative of a coherent set of modest but significant improvements, integrated to produce the step change we desire: essentially, a reduction of processing energy to below 40%, which we believe is achievable without recourse to any mystical machines. A key underlying capability to designing these dramatically improved processes, is the weaving of independent process models into a coherent circuit simulation, in order to design the new generation of mineral processing circuits. Keywords: step change, circuit design, circuit simulation, energy reduction

Sep 1, 2012

By V. E. Vigdergauz

Possibilities of the analysis of potential energy of bubble-particle interaction on the basis of extended DLVO theory are discussed. Interaction energies of mineral silica, coal and pyrite particles with contact angles from 20 to 100 degrees and air bubbles in neutral and alkaline solutions are analyzed. It is shown that for hydrophilic silica, the formation of particle-bubble complexes (either in the area of primary or secondary potential minima) is impossible due to the high potential barriers (from 6000 to 140000 kT)and low values of the attraction force. There is shown that for coal and pyrite particles the energy of interaction vs. particle-bubble distance strongly depends on pH value. Improvement of floatability of minerals by the hydrophobization of their surface by collectors leads to the eliminating of potential barriers and the formation of the stable complexes of minerals and air bubbles in the area of primary potential minimum. In addition, due to hydrophobization of coal and pyrite changing pH has practically no influence on the energy of interaction. There are discussed results of the numerical calculations of normalized interaction forces in particle-bubble systems on the nanometer distances for pyrite, sphalerite, and chalcopyrite at contact angles up to 85° in comparison with the experimental data. The values of adhesion force for hydrophobized particles of coal and pyrite to air bubbles are about 10-5 N, that indicates stability of the formed flotation complexes. Examples of using the long-range and high-energy effect of hydrophobic interactions for improving minerals floatability are discussed. There are illustrated minerals wettability changes induced by the adsorption of thiol collector and hydrophobic polymer. Possibilities of flocculation and flotation of mineral slimes due the polymer-collector hydrophobic interactions are shown. Keywords: bubble-particle interaction, contact angle, extended DLVO theory, floatability

Sep 1, 2012